I went for a longer ride today (just over 200km) to carry on with running-in and try to get the carb jetted a bit better.
I have quite a range of jets but (in true fashion ) the size atomiser I need is one I haven't got! P2 works well enough, but could be a little lean, while P5 is slightly too rich. I'll have to obtain a P4 (and/or perhaps a P3 if available) and do more testing before deciding. Having said that, the bike was easily rideable with either atomiser fitted.

Cooling seems marginal - OK while moving along briskly, but the water temperature needle soon creeps up while in "gridlock" or slow-moving traffic. As I was nearing the end of my ride the sun went down, which seemed to give slightly lower temperatures. I'll defer consideration of any modifications to improve cooling (e.g. larger radiator, electric fan etc.) until I get a better idea of how consistent the existing set-up is.

I took this photo on Lenore Drive at Eastern Creek, near Sydney West Substation:

When I got back, I noticed some unburnt mixture leaking from the silencer joint. I had previously got my machinist to make this adaptor to join the DFR silencer to the Jackal pipe:
On dismantling, I found that I hadn't applied any sealer to the joint between the adaptor and silencer! Luckily an easy fix...

If it is of any use to anyone, here are the carb settings I have ended up with so far. The carb itself has been converted to TZR250 1KT Formula 3 specification and the air intake system uses a K&N filter, as described and pictured earlier.

I could probably still go down a size or two on the main jet, but I'll leave it where it is for the time being. The ideal throttle slide cutaway is probably somewhere between 0 and 1.5. I have tried both and prefer the 0, although either is usable. If I want to get any closer, I'll have to modify a 0 slide to 0.5 or 1.0.

For anyone wanting to fit stronger clutch springs, I have compiled some info which may be of interest.

I have compared three other genuine Yamaha springs to the standard SDR spring (all springs new) using an instrument normally used for checking valve springs. This gave an indication (in pounds) of the force required to compress the spring and I took readings just before each spring became coilbound.

The springs above all have the same outside diameter and are made using wire of the same diameter. At the time of writing, they are all still available from Yamaha.
As will be seen, the DT200 and DT230 springs required about the same force to compress, although the DT200 springs are slightly longer. I am using the pink DT200 springs in my SDR and clutch performance seems entirely satisfactory.

I just joined the forum to say well done on this fantastic thread of info on the SDR. I just bought one after seeing a red SDR parked on a street in Crows Nest about six months ago. It wasn't yours was it? I've been keeping an eye out to see if it re-appeared there so I could leave a note asking if I could purchase it, it looked fantastic!

Hope to learn more about the SDR and maybe even contribute something after I get it sorted.

I've been going through SDR200.com and will be picking up kits for a new top-end and engine mounts to start with._________________RG500 Gamma
MC21SP
RS250 Mk2
SDR200
YZ125
Some four strokes

I just bought one after seeing a red SDR parked on a street in Crows Nest about six months ago. It wasn't yours was it?

No, not mine...I don't like to leave it parked on the street for too long! Still, its unusual to see one anywhere out & about. Let me know if you need any info or assistance with any aspect of your own project bike.

Sub'ing to read over everything when I get some down time, love the attention to detail. Very well documented and organized project thread. Great work, the SDR came out looking fantastic!! I wish I could find one of these goobers over here in the states

I have now added the chrome extension and the pictures are great! I need more info on the 3rd engine mounting that you are doing. I have also looked at the Tosh-Tec ones and had thought about making one up. Any info you have on this would be greatly appreciated.
I managed to track down 2 NOS rear engine mountings some years back and fitted them in mine when i rebuilt the motor a couple of years ago. The bush also fitted a quad if i remember correctly and a guy here in the uk had one.
I also ordered one of the 'shim' rubber spacers from sdr200.com to fit at the same time. As for the fronts i replaced the bushes which helped massively.